RECYCLE OF LEAD ACID BATTERY

(LEAD REFINING PROCESS)

[CODE NO.3822]

About 60% of lead produced world-wide is derived from ore. Lead ore is minedin many
countries around the world, though three quarters of world output comesfrom only six
countries: China, Australia, USA, Peru, Canada and Mexico. Smallamounts are mined
in several countries in Europe, with the biggest producer being Sweden. Total
production has been at a similar level since the 1970s; new mines open or are
expanded to replace old mines. (Note: all these mines contain at least two metals (also
zinc, sometimes silver, gold and copper) so lead extraction is not the only reason for the
mining.).

Lead is naturally sourced from an ore called Galena. However the biggest ore of Lead
Available above the Surface of the Earth are various types of Lead Scraps. Lead Acid
Battery Scrap being the primary source of Lead Scrap. There are other sources of Lead
Scrap as well but any Lead Recycling plant can be confidently dependent on Lead Acid
Battery Scrap as its continuous and consistent source of Raw Material.

Lead is the 4th most widely used Metal on earth.Lead has highest rate of recycling
among all Ferrous & Non-Ferrous Metals.Lead is the only metal on earth which retains
its 100% Chemical & Physical properties, irrespective of any number of
recycling.Worldwide production of recycled Lead is now about 3 times more than
producing Prime Lead.

Lead Acid Batteries Come fit with any vehicle and have a fixed life. After their usage,
the batteries are collected by the Dealer who is fitting a new battery in the vehicle. For
the returned old battery the dealer of course considers a discount on the new battery.
This way the Scrap batteries are sourced and the channelized to various scrap dealers
and through them to Lead recycling Plants. This way the Scrap Battery finds its way to
be recycled.

Recycling by definition is the reuse of materials, either pre-consumer or post-consumer,

that would ordinarily be considered waste. Recycling helps lessen the amount of waste
that goes into landfills, helps reduce the amount of toxic chemicals absorbed into the
earth and, in some cases, significantly reduces manufacturing costs and energy
consumption.
Battery Recycling is good for the Earth and good for future generations. Battery
Recycling is the act of processing used or abandoned Batteries, which would otherwise
be considered waste and harmful to our environment. Many communities have
curbside Battery Recycling services to help out and there are Battery Recycling centers
all across the country where Spent Battery can be brought. Often times Battery
Recycling centers pay you for dropping Spent Battery off, so it’s a win-win situation.

Lead can end up in water and soils via corrosion of leaded pipelines in water
transporting procedure and through corrosion of leaded paints. It cannot be broken
down; it can only be converted to other forms.

Lead accumulates in the bodies of water organisms and soil organisms. These will
experience health effects from lead poisoning. Health effects on shellfish can take place
even when only very small concentrations of lead are present. Body functions of
phytoplankton can be disturbed when lead interferes. Phytoplankton is an important
source of oxygen production in seas and many larger sea-animals consume it. That is
why we now start to wonder whether lead pollution can influence worldwide balances.

Several Battery Recycling Plants are end point of this supply chain. These Factories
Break these batteries and Extract Lead bearing material which is then fed in to the
Smelting Furnaces. This Lead Bearing Material is a mix of Lead and Lead Oxide. This
mixture is smelted in Smelting Furnaces to Produce Cure Lead.
This crude Lead is later refined to a purity of 99.98%. This Lead Produced will now find
its way towards a Lead Acid Battery Manufacturing company. The loop is closed here
and the cycle begins again.

Lead Acid Batteries are recyclable due to the very nature of Lead. Lead can be recycled
almost any number of times. Of course there are process losses but this recyclability of
Lead has brought environmental and business sustainability to the Lead Acid battery
Industry. Lead Acid Batteries have been irreplaceable for past several years due to this
very important factor. Lithium Ion batteries fail miserably in the recyclability factor.
Currently the process is not profitable for Entrepreneurs Individually and also the
process is too complex due to the complex chemistry of the Lithium Ion Batteries.

Lead Acid Battery Recycling Plant / Battery Recycling Plant Owners should be
responsible enough to know that Lead is toxic and should can cause harm to the
environment / people if not handled properly. They should select the best of Equipment
to make sure that profits are made but sustainably and responsibly.
The battery contains 70% lead, 20% acid and 10% plastic case. In recycling process
batteries are broken cover of batteries is removed and acid is drained out for
neutralization. Top portion is hammered for shredding of plastic and the lead posts fixed
in the top are released. Furnace smelting is done for approximately 5 hours at over
1000ᵒC lead and slag is tapped separately. Refining is done by lowering the
temperature thereby decreasing the solubility of impurities.

COST ESTIMATION

Plant Capacity 40 MT/Day

Land & Building (1000 sq.mt.) Rs. 62 Lac
Plant & Machinery Rs. 1.25 Cr
Working Capital for 1 Month Rs. 11.43 Cr
Total Capital Investment Rs. 13.47 Cr
Rate of Return 92%
Break Even Point 21%

INTRODUCTION
FACTORS INFLUENCING HIGH COLLECTION RATES OF LEAD ARE:
RECYCLING PROCESSES
LOCATION FOR PLANT
SOME AMAZING BENEFITS OF BATTERY RECYCLING
REDUCTION IN WASTE SENT TO LANDFILLS AND TURNING THEM INTO
NEW PRODUCTS
COMPOSITION OF REFINED LEAD / PURE LEAD
PURE LEAD SPECIFICATION
COMPOSITION OF REFINED LEAD / PURE LEAD
AVAILABLE BATTERY TYPES
A) ACID VS. ALKALINE
WET VS. DRY
CATEGORIES
VEHICULAR BATTERIES
I) LEAD-ACID
THE CHEMICAL REACTION IN A LEAD-ACID BATTERY:-
II) SEALED VS. FLOODED
III) DEEP-CYCLE BATTERIES
BATTERY CATEGORIES FOR VEHICULAR BATTERIES
IV) "HOUSEHOLD" BATTERIES
RECYCLING OF MAJOR LEAD PRODUCTS
LEAD-ACID BATTERIES
COLLECTION OF BATTERIES
PREPARATION OF LEAD-ACID BATTERIES
REFINING/COMPOSITION CONTROL
ADDITION OF OTHER TYPES OF SCRAP
SHEET, PIPING, CABLE SHEATHING
END-OF-LIFE VEHICLES
ELECTRICAL AND ELECTRONIC PRODUCTS
CATHODE RAY TUBES
CONSTRUCTION OF SEALED LEAD ACID BATTERIES
REACTIONS OF SEALED LEAD ACID BATTERIES:-
SEALED LEAD ACID BATTERIES CHARACTERISTICS
BATTERY CAPACITY
BATTERY VOLTAGE
BATTERY SELF-DISCHARGE
THE ABOVE DATA IS SHOWN IN THE FOLLOWING GRAPH
BATTERY INTERNAL RESISTANCE
BATTERY LIFE
LEAD INGOT APPLICATIONS
LEAD INGOTS
BATTERY
ROLLED EXTRUSIONS
PIGMENTS
CABLE SHEATHING
LEAD INGOTS FOR CAST LEAD BULLETS
LEAD ALLOYS
BATTERY SCRAP – RAW MATERIAL FOR RECYCLING
DESIGN OF A STARTER BATTERY
RECYCLING OF LEAD-ACID BATTERIES
GENERAL CONSIDERATIONS
TECHNICAL STEPS IN BATTERY RECYCLING
DISMANTLING OF BATTERY CASES AND FEED PREPARATION
HAMMER MILL CRUSHING WHOLEBATTERIES
FIG- HAND SORTING OF COARSE FEEDFRACTION
HAND SORTING OF COARSE FEED FRACTION
MELTING AND REDUCTION OPERATIONOF PASTE AND BATTERY FINES
FIG. : ROTARY DRUM FURNACE FOR BATTERYSCRAP RECYCLING
MELTING OF GRIDS, TERMINALS ANDBRIDGES
REFINING OF CRUDE LEAD
FIG. :- REFINING OF CRUDE LET IN A KETTLE
GAS CLEANING SYSTEM
FIG. : OFF-GAS CLEANING SYSTEM OF A LEADRECYCLING FURNACE
RECYCLE OF LEAD ACID BATTERY PROCESS
(LEAD REFINING PROCESS)
PROCESS DESCRIPTION
SCRAP PRETREATMENT
SMELTING -
PRETREATMENT
SMELTING:-
REFINING
REFINING -
LEGISLATION ON BATTERY SCRAP
SALIENT FEATURES OF BATTERIES LEGISLATION
OPERATIONAL ASPECTS OF BATTERY CHANNELIZATION
IMPACT OF BATTERIES LEGISLATION ON SUPPLY-DEMAND
MARKET SURVEY
GREEN RECYCLING
GLOBAL PICTURE
KEY MARKET PLAYERS
SUPPLY-DEMAND OF LEAD SCRAP IN INDIA
THE MARKET SIZE
COST, RECYCLABILITY: MAJOR ADVANTAGES
TRADE IN LEAD
CONSUMPTION OF LEAD
LEAD-ACID BATTERIES
THE COMPOSITION OF AN AVERAGE LEAD-ACID BATTERY
THE APPLICATIONS OF LEAD AND LEAD-ACID BATTERIES
THE PROPORTION OF DIFFERENT BATTERY TYPES USED IN ELECTRIC
BICYCLES
INDIAN SCENARIO
BATTERY COLLECTION
LEAD ACID RECYCLING EQUIPMENTS
SMELTING
REFINING
INGOT STACKING MACHINE
BATTERY BREAKING AND SEPARATION
REFRACTORY
BATTERY CUTTING MACHINE
POLLUTION CONTROL EQUIPMENT & MATERIAL HANDLING
IMPACT OF IMPROPER BATTERY DISPOSAL
GLOBAL HEALTH IMPACT OF IMPROPER BATTERY DISPOSAL
LEGAL IMPACT OF IMPROPER BATTERY DISPOSAL
FINANCIAL IMPACT OF DISPOSING BATTERIES
ANALYTICAL CONSIDERATIONS –L
ANALYTICAL CONSIDERATIONS - FIELD SCREENING METHODS FOR LEAD
GREEN RECYCLING OF USED LEAD ACID BATTERIES (ULAB)
GUIDELINES/STANDARD OPERATING PROCEDURES FOR THE
ENVIRONMENTALLY SOUND MANAGEMENT/RECYCLING OF ULAB
BEYOND COMPLIANCE MEASURES IN ULAB RECYCLING INDUSTRY
PROCESS FLOW DIAGRAM
THE WHOLE LINE FOR LEAD BATTERY RECYCLING
PHOTOGRAPHS OF PRODUCT
LEAD BATTERY – TOUCHES OUR LIVES
SUPPLIER OF MACHINERY
ACS LEAD TECH
MACHINERY PHOTOGRAPHS
SMELTING
REFINING
INGOT CASTING MACHINE
BATTERY BREAKING AND SEPARATION
REFRACTORY
BATTERY CUTTING MACHINE
POLLUTION CONTROL EQUIPMENT& MATERIAL HANDLING
AW MATERIALS PHOTOGRAPHS
RECEIVING
FINAL PRODUCT

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)